U.S. patent application number 12/009937 was filed with the patent office on 2009-03-26 for wireless communication device with internal antenna system for use in hazardous locations.
This patent application is currently assigned to IP Sensing, Inc.. Invention is credited to William Bret Boren.
Application Number | 20090081963 12/009937 |
Document ID | / |
Family ID | 40472180 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090081963 |
Kind Code |
A1 |
Boren; William Bret |
March 26, 2009 |
Wireless communication device with internal antenna system for use
in hazardous locations
Abstract
A self-contained radio frequency (RF) wireless communication
device (100) comprising an explosion-proof housing (110), an
internal electronic system for the conversion of radio wave and
conducted electrical signals, and an internal antenna system
located within a non-metallic portion (130) of the housing for
collecting and emitting radio wave energy. The antenna system
enables the wireless communication device (100) to safely collect
and emit radio wave energy using one or more optimally configured
antenna resonators (351), with each antenna resonator differing
each other antenna resonator by at least one attribute in a group
of attributes comprising: frequency response, field polarization,
and wavelength spatial diversity. The present invention is a
self-contained RF wireless communication device that provides data
communications between two or more devices for the supervisory
control and/or data acquisition of actuators, sensors, transducers,
gas detectors, and other devices located in explosive hazardous
locations without the need of installing one or more external
antennas, one or more antenna connectors, excessive conduit
connections and seals, and the like, whereby reducing system
installation components count and eliminating conduit connections,
furthermore reducing the probability of system-level failures
caused by lower-level faults of components and conduit connections,
resulting in a less expensive and safer electrical equipment
installation.
Inventors: |
Boren; William Bret;
(Southlake, TX) |
Correspondence
Address: |
WILLIAM BRET BOREN
1000 BREEZE WAY
SOUTHLAKE
TX
76092
US
|
Assignee: |
IP Sensing, Inc.
Southlake
TX
|
Family ID: |
40472180 |
Appl. No.: |
12/009937 |
Filed: |
January 23, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60897657 |
Jan 26, 2007 |
|
|
|
Current U.S.
Class: |
455/90.1 |
Current CPC
Class: |
H04B 1/40 20130101; H01Q
11/08 20130101; H01Q 1/002 20130101; H01Q 21/30 20130101 |
Class at
Publication: |
455/90.1 |
International
Class: |
H04B 1/38 20060101
H04B001/38 |
Claims
1. A wireless communication device for transferring radio wave
energy to and from a dynamic system, attenuating heat energy
intensity produced by said dynamic system, and controlling pressure
forces produced by said dynamic system, whereby enabling said
dynamic system to communicate with external devices using radio
wave communication methods without igniting a surrounding
atmosphere of explosive elements concentrations, comprising: (a)
means for capturing said dynamic system in a capsule, whereby
containing ignition sources and explosive elements of said dynamic
system in the confined capsule interior, (b) means for propagating
said dynamic system generated radio wave energy through said
capsule walls, whereby transferring radio wave signals between said
dynamic system within capsule interior and external devices beyond
capsule walls, (c) means for absorbing heat energy produced by said
dynamic system into said capsule walls, whereby preventing the
ignition of explosive elements surrounding said capsule by reducing
the temperature of heat energy while traveling a path from the
capsule internal region to the capsule external region, (d) and
means for trapping under pressure the hot gases produced by said
dynamic system within interior of said capsule, whereby preventing
hot gases and flames produced by an explosion within the capsule
from escaping capsule walls to the surrounding atmosphere of
capsule.
2. A wireless communication device for transferring radio wave
energy to and from a dynamic system, attenuating heat energy
intensity produced by said dynamic system, and controlling pressure
forces produced by said dynamic system, whereby enabling said
dynamic system to communicate with external devices using radio
wave communication methods without igniting a surrounding
atmosphere of explosive elements concentrations, comprising: (a)
means for capturing said dynamic system in a capsule, whereby
containing ignition sources and explosive elements of said dynamic
system in the confined capsule interior, (b) means for propagating
said dynamic system generated radio wave energy through said
capsule walls, whereby transferring radio wave signals between said
dynamic system within capsule interior and external devices beyond
capsule walls, (c) means for conducting electrical energy to and
from said dynamic system through capsule walls, whereby
transferring conducted electrical energy between said dynamic
system within capsule interior and external devices beyond capsule
walls, (d) means for absorbing heat energy produced by said dynamic
system into said capsule walls, whereby preventing the ignition of
explosive elements surrounding said capsule by reducing the
temperature of heat energy while traveling a path from the capsule
internal region to the capsule external region, (e) and means for
trapping under pressure the hot gases produced by said dynamic
system within interior of said capsule, whereby preventing hot
gases and flames produced by an explosion within the capsule from
escaping capsule walls to the surrounding atmosphere of
capsule.
3. A wireless communication device of claim 2, comprising: (a) a
capsule comprising: i. a conduit fitting portion, wherein the
conduit fitting portion comprises: A. a fitting defining conduit
fitting portion first end and conduit fitting portion second end,
B. a hollow cavity between said conduit fitting portion first end
and conduit fitting portion second end, C. a threaded connection at
said conduit fitting portion first end, D. a joint mating section
at said conduit fitting portion second end; ii. a non-metallic
portion, wherein the non-metallic portion comprises: A. a pressure
vessel defining non-metallic portion first end and non-metallic
portion second end, B. a hollow cavity between said non-metallic
portion first end and non-metallic portion second end, C. a joint
mating section at said non-metallic portion first end, D. a closed
off said non-metallic portion second end, whereby said pressure
vessel has only one opening at the said non-metallic portion first
end; iii. means for joining said conduit fitting portion second end
to said non-metallic portion first end; (b) an antenna system,
whereby providing the wireless communication device a means to
radiate and collect radio wave energy, i. wherein the antenna
system is located within the non-metallic portion of said capsule,
ii. wherein the antenna system comprises one or more antenna
resonators; (c) an electronic system, whereby providing the
wireless communication device a means of converting between forms
of radio wave signals and conducted electrical signals, i. wherein
the electronic system is located within the capsule, ii. wherein
the electronic system comprises: A. at least one printed circuit
board, B. at least one power supply portion, C. at least one data
converter portion, D. a plurality of conduit port electrical
conductors, E. an RF transceiver, F. and said antenna system; (d)
and a conduit port, whereby providing the wireless communication
device an electromechanical interface to external devices, i.
wherein said conduit port is an integral part of the said conduit
fitting portion of said capsule, ii. wherein said conduit port has
within said plurality of conduit port electrical conductors, iii.
wherein said conduit port is filled with a conduit sealing
compound, whereby creating a factory-installed conduit seal, iv.
wherein said conduit port first end has a threaded section, whereby
providing a means for connecting conduit fitting portion first end
to an external rigid metal conduit compatible fitting.
4. A wireless communication device for transferring radio wave
energy to and from a dynamic system, attenuating heat energy
intensity produced by said dynamic system, and controlling pressure
forces produced by said dynamic system, whereby enabling said
dynamic system to communicate with external devices using radio
wave communication methods without igniting a surrounding
atmosphere of explosive elements concentrations, comprising: (a)
means for capturing said dynamic system in a capsule, whereby
containing ignition sources and explosive elements of said dynamic
system in the confined capsule interior, (b) means for propagating
said dynamic system generated radio wave energy through said
capsule walls, whereby transferring radio wave signals between said
dynamic system within capsule interior and external devices beyond
capsule walls, (c) means for conducting electrical energy to and
from said dynamic system through capsule walls, whereby
transferring conducted electrical energy between said dynamic
system within capsule interior and external devices beyond capsule
walls, (d) means for absorbing heat energy produced by said dynamic
system into said capsule walls, whereby preventing the ignition of
explosive elements surrounding said capsule by reducing the
temperature of heat energy while traveling a path from the capsule
internal region to the capsule external region, (e) and means for
trapping under pressure the hot gases produced by said dynamic
system within interior of said capsule, whereby preventing hot
gases and flames produced by an explosion within the capsule from
escaping capsule walls to the surrounding atmosphere of
capsule.
5. A wireless communication device of claim 4, comprising: (a) a
capsule comprising: i. a conduit fitting portion, wherein the
conduit fitting portion comprises: A. a fitting defining conduit
fitting portion first end and conduit fitting portion second end,
B. a hollow cavity between said conduit fitting portion first end
and conduit fitting portion second end, C. a threaded connection at
said conduit fitting portion first end, D. a joint mating section
at said conduit fitting portion second end; ii. a non-metallic
portion, wherein the non-metallic portion comprises: A. a pressure
vessel defining non-metallic portion first end and non-metallic
portion second end, B. a hollow cavity between said non-metallic
portion first end and non-metallic portion second end, C. a joint
mating section at said non-metallic portion first end; iii. means
for joining said conduit fitting portion second end to said
non-metallic portion first end; (b) an antenna system, whereby
providing the wireless communication device a means to radiate and
collect radio wave energy, i. wherein the antenna system is located
within the non-metallic portion of said capsule, ii. wherein the
antenna system comprises one or more antenna resonators; (c) an
electronic system, whereby providing the wireless communication
device a means of converting between forms of radio wave signals
and conducted electrical signals, i. wherein the electronic system
is located within the capsule, ii. wherein the electronic system
comprises: A. one or more printed circuit boards, B. one or more
power supply portions, C. one or more data converter portions, D.
plurality of conduit port electrical conductors, E. at least one RF
transceiver, F. said antenna system, G. and plurality of
intrinsically safe interface port electrical conductors; (d) a
conduit port, whereby providing the wireless communication device
an electromechanical interface to external devices, i. wherein said
conduit port is an integral part of the said conduit fitting
portion of said capsule, ii. wherein said conduit port has within
said plurality of conduit port electrical conductors, iii. wherein
said conduit port is filled with a conduit sealing compound,
whereby creating a factory-installed conduit seal, iv. wherein said
conduit port first end has a threaded section, whereby providing a
means for connecting conduit fitting portion first end to an
external rigid metal conduit compatible fitting; (e) and one or
more intrinsically safe circuit interface ports, i. wherein at
least one intrinsically safe circuit interface port is an integral
part of the said non-metallic portion of said capsule, ii. wherein
said one or more intrinsically safe circuit interface ports have
said plurality of intrinsically safe circuit interface port
electrical conductors, iii. wherein the one or more intrinsically
safe circuit interface ports are filled with an encapsulated
enclosure casting compound to create an intrinsically safe
electrical barrier between capsule walls and plurality of
intrinsically safe circuit interface port electrical
conductors.
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. The process of providing a wireless communication device in an
explosion-proof housing for use in a hazardous location capable of
providing a means for transmitting and receiving conducted
electrical energy by one or more electromechanical interface ports
comprising at least one conduit port with factory-installed conduit
seal and at least one intrinsically safe interface port, whereby
allowing external equipment and devices such as transducers,
actuators, sensors, and other devices to benefit from data transfer
using conducted electrical and wireless communication, by using the
wireless communication device of claim 4.
13. (canceled)
14. (canceled)
15. The process of providing a wireless communication device in an
explosion-proof housing comprising conduit port with
factory-installed conduit seal, an internal antenna system, and one
or more intrinsically safe interface ports without the dependence
of a separate explosion-proof enclosure, or separate transceiver,
or a separate antenna, or separate antenna connector, or separate
conduit seals by using the wireless communication device of claim
4.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS AND INFORMATION
DISCLOSURE
[0001] This application claims benefit of U.S. Provisional
Application Ser. No. 60/897,657 filed Jan. 26, 2007.
TABLE-US-00001 6,900,565 May, 2005 Preston 7,057,577 June 2006
Willoughby, et al. 7,014,502 March 2006 Rasmussen 6,978,165
December 2005 Martinez, et al. 6,967,589 November 2005 Peters
6,894,659 May, 2005 Pepperling, et al. 6,794,991 September 2004
Dungan 6,369,715 April 2002 Bennett, Jr., et al.
OTHER REFERENCES AND DISCLOSURE INFORMATION
[0002] 1. Titan Industries, Inc. publication entitled "CK-485MX
Wireless Transceiver", document number DOC485MX, version 2.0, pages
2-6, author Dr. Brian Kopp, published Jun. 6, 1997 and downloaded
from the www.titan-solutions.com on Dec. 26, 2006. [0003] 2. Titan
Industries, Inc. publication entitled "RTU System Radio
Installation", document number TI-INSTALL-1, rev 0, sheet 1 of 1,
drawn by Lloyd, dated May 17, 1999 and downloaded from the website
www.titan-solutions.com on Dec. 26, 2006. [0004] 3. Honeywell Inc.
publication entitled "XYR5000 Series Wireless Transmitters", pages
1-8, published prior to Dec. 26, 2006 and downloaded from the
website www.lesman.com on Dec. 26, 2006. [0005] 4. Detcon Inc.
publication entitled "Detcon's Model Series 700, Environmentally
Bulletproof, Gas Detection Sensors", Catalog #700-0806, page 5 of
6, published prior to Jan. 1, 2007 and downloaded from the website
www.detcon.com on Dec. 26, 2006. [0006] 5. IP Sensing, Inc.,
publication entitled "In-ground Radio Technical Specifications",
author Bret Boren, pages 1-2, published Jun. 22, 2006, published at
Axxea Systems as sales material and presented to public June 2006.
[0007] 6. IP Sensing, Inc., publication entitled "RS485 Transponder
Unit", author Bret Boren, sheets 1-2, published Oct. 19, 2006,
published at Axxea Systems as sales material and presented to
public October 2006. [0008] 7. IP Sensing, Inc., publication
entitled "Explosion-proof RS485 Transponder Unit", author Bret
Boren, sheets 1 of 1, published Oct. 24, 2006, published at Axxea
Systems as sales material and presented to public October 2006.
[0009] 8. IP Sensing, Inc., publication entitled
"IPS120A1--Stainless Steel Cap", author Bret Boren, sheets 1 of 1,
published Oct. 16, 2006, published at Axxea Systems as
manufacturing specification for engineering prototype. [0010] 9. IP
Sensing, Inc., publication entitled "IPS119A1--Black ABS Tube",
author Bret Boren, sheets 1 of 1, published Oct. 16, 2006,
published at Axxea Systems as manufacturing specification for
engineering prototype.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0011] "Not Applicable"
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM
LISTING COMPACT DISC APPENDIX
[0012] "Not Applicable"
BACKGROUND OF THE INVENTION
[0013] 1. Field of the Invention
[0014] The present invention is related to a wireless communication
device, and more particularly to a wireless communication device
having a radio frequency (RF) transceiver, an internal antenna
system, data converter circuitry, and a particular housing design
dependent on the internal antenna system and hazardous location
electrical equipment installation requirements.
[0015] 2. Background Art
[0016] There are many applications today where electrical
connections are made in hazardous environments, such as locations
where ignitable concentrations of flammable gases, vapors or
liquids are present or may become present through accident or
abnormal operation. Hazardous locations comprise areas such as
hydrocarbon drilling operations, natural gas processing and
transmission facilities, as well as dust-laden operations such as
grain processing facilities. For instance, Article 500 of the
National Electrical Code ("NEC") NFPA 70 has classified certain
locations as hazardous, including Class I (combustible material in
the form of gas vapors) and Class II (combustible material in the
form of dust).
[0017] Electrical devices mounted in hazardous locations are
generally required to be in an explosion-proof enclosure or be
classified as intrinsically safe. By mounting electrical devices in
explosion-proof enclosures, the likelihood of an explosion caused
by electrical arching, such as opening and closing of a contact or
non-sealed relay device, is significantly reduced. An
explosion-proof enclosure is not necessary if the electrical device
is classified as intrinsically safe, which generally means the
circuits of the device are of such low power that they are
incapable of causing ignition. However, performance of many
electrical devices is degraded when power is limited and the lack
of performance must be compensated with installation of additional
system components elsewhere.
[0018] As required by the NEC, electrical wiring/cable in hazardous
locations are required to pass through a rigid metal conduit
connection system from location to location, such as from an
instruments enclosure housing to a junction box outside the
instrument or to the plant electrical distribution system. The NEC
requires that explosion-proof conduit seals be installed in the
rigid metal conduit connections to prevent hazardous gases, vapors
or flames in one region of the electrical installation from passing
to another region through the conduit pipe connection in the event
of an internal explosion. However, these conduit seals are
expensive and their installation is labor intensive. Furthermore,
removal of the seal for maintenance or service of the electrical
system is exceedingly difficult and typically requires either
cutting the seal fitting off of the conduit system or chipping away
the sealing compound contained within the fitting, which either
method may result in accidentally cutting the wire/cable contained
therein.
[0019] Wireless communication systems are common electrical
equipment installed in hazardous locations used for maintaining
processes and safety by supervisory control and data acquisition of
equipment, such as gas detectors, pressure sensors, and shutoff
valves. As will be shown herein, the referenced related art
demonstrates the installation of wireless communication devices in
hazardous locations to involve numerous system components, such as
explosion-proof enclosures, conduit seals, antenna connectors, and
antennas, to complete a wireless communication system installation.
The industrial marketplace drives for safer electrical equipment
installations in hazardous locations by reducing the number of
system components required in the installation. The reduction of
the system components count and conduit connections in an
installation inherently reduces the probability of system-level
failures caused by lower-level faults of the components and conduit
connections. The desirability of creating a safer wireless system
while reducing components and conduit connections provides
challenges to the device designers in achieving optimal system
performance, and more particularly as in the present invention,
optimizing antenna system performance using a multiple antenna
diversity system.
[0020] U.S. Pat. No. 7,057,577 to Willoughby, et al., June 2006,
(assigned to Ventek, LLC of West Chester, Ohio). This prior art
invention provides the ability to adapt a standard RF antenna for
use as a component in a hazardous location. However, separate
components including an explosion-proof enclosure, RF transceiver,
and RF antenna are needed to complete the wireless communication
system. The present invention is a complete explosion-proof,
self-contained wireless communication device with built-in system
components including an RF transceiver, one or more RF antennas,
and a conduit seal thus making installation safer by reducing the
need for separate system components and the required conduit
connections and seals between the separate components.
[0021] U.S. Pat. No. 7,014,502 to Rasmussen, March 2006, (assigned
to AnLynk Wireless, LLC of Columbus, Ohio). This related art
invention attempts to provide an RF antenna component for use in a
hazardous location to simplify installation of a wireless system.
However, an explosion-proof enclosure, an RE transceiver, coaxial
cabling, and conduit seals are still needed to complete the
wireless communication system using this device and therefore
requiring additional components in the system, thereby increasing
the probability for system-level failures caused by lower-level
faults at the components and conduit connections. The present
invention is a complete explosion-proof, self-contained wireless
communication device with built-in system components including an
RF transceiver, one or more RF antennas, and a conduit seal thus
making installation safer by reducing the need for separate system
components, required conduit connections, and seals between the
separate components.
[0022] U.S. Pat. No. 6,900,565 to Preston, May 2005, (assigned to
Airex Corporation of Anaheim, Calif.). This related art invention
demonstrates a motor controller apparatus with a claim of
explosion-proof compliance with the National Electrical Code, NFPA
70 and shows similar engineering challenges in designing an
explosion-proof product for installation and use in hazardous
locations.
[0023] U.S. Pat. No. 6,978,165 to Martinez, et al., December 2005,
(assigned to Motorola, Inc. of Schaumburg, Ill.). Like the present
invention, this related art invention discloses an apparatus with
an RF transceiver and built-in RF antenna system used to provide
wireless communication. Unlike this present invention which is
capable of installation at an explosive hazardous location, this
related art device does not have the difficult design requirements
and limitations as an apparatus used in an explosive hazardous
location. Integration of system components into a single apparatus
as with this related art is desirable to achieve a compact, less
expensive, and safer product solution. As with the present
invention, integration is desirable for the increase in safety by
reducing the probability of system-level failures caused by
lower-level faults. The desirability of a more compact and safer
wireless communication system provides challenges to the design
engineers in achieving optimal antenna performance, much like the
challenges of antenna design referenced in this related art
patent.
[0024] U.S. Pat. No. 6,967,589 to Peters, November 2005, (assigned
to OleumTech Corporation of Irvine, Calif.). This related art
invention solves the problem of wireless communication in a
hazardous location by operating a low-power RF transceiver and its
RF antenna at an intrinsically safe power level that is incapable
of causing an ignition in the hazardous location. A high-power RF
transceiver and its RF antenna are then installed a short distance
away in a non-hazardous location to relay the wireless
communication data to a further distant base station. An apparent
problem with this invention is the intrinsically safe low-power RF
transceiver limits the distance performance of the wireless
communication device and therefore requires additional electrical
equipment to extend the wireless communication distance and
therefore more system components to increase probability of system
level-failures. This present invention enables the placement of a
high-power RF transceiver and one or more RF antennas directly in
the hazardous location, thereby directly enabling high-performance
long distance wireless communication with the single equipment
installation.
[0025] U.S. Pat. No. 6,894,659 to Pepperling, et al., May 2005,
(assigned to Daniel Industries, Inc. of Houston, Tex.). This
related art invention discloses a common solution to providing
wireless communication in a hazardous location with the
installation of a RF transceiver in an explosion-proof enclosure
and then mounting its RF antenna external to the enclosure.
However, the invention does not address the complex problem of
coupling the RF transceiver to its RF antenna while meeting the
requirements for electrical equipment installation in hazardous
locations. The present invention meets the requirements for
placement of both the RF transceiver and one or more RF antennas in
a hazardous location, furthermore reducing system component count
and improving safety.
[0026] U.S. Pat. No. 6,794,991 to Dungan, September 2004, (assigned
to Gastronics' Inc. of Cleveland, Ohio). This related art invention
discloses a wireless communication monitoring system for use in a
hazardous location and the need for such type of a system for
supervisory control and data acquisition. The related art patent
discloses an RF transceiver installed in an explosion-proof
enclosure and a separate antenna external to the enclosure using an
antenna connector such as the one described in the referenced
Willoughby, et al. U.S. Pat. No. 7,057,577 patent. The present
invention addresses the wireless communication installation with
less system components using a complete explosion-proof,
self-contained wireless communication apparatus that includes a
built-in RF transceiver and one or more RF antennas thus reducing
system component count and improving safety.
[0027] U.S. Pat. No. 6,369,715 to Bennett, Jr., et al., April 2002,
(assigned to Innovative Sensor Solutions, LTD of Houston, Tex.).
This related art invention discloses a wireless communication
apparatus for use in a hazardous location and the need for such
type of devices. The invention solves the problem of wireless
communication in a hazardous location by operating a low-power RF
transceiver and its RF antenna at an intrinsically safe power level
incapable of causing an ignition in the hazardous location and then
installing a high-power RF transceiver and its RF antenna a short
distance away in a non-hazardous location to relay the wireless
communication data. The present invention is not restricted by the
intrinsically safe electronics requirements in limiting RF
transmitter power and therefore has substantially longer distance
and does not require a radio repeater to gain distance. This prior
art patent further discloses in "Background of the Invention" some
difficulties encountered when attempting to design an apparatus
where the RF transceiver and RF antenna are integrated together in
an explosion-proof enclosure as the innovative invention has
successfully achieved, therefore, giving additional evidence on the
unobviousness and novelty of the present invention by those skilled
in the art.
[0028] As shown in the related art of Bennett U.S. Pat. No.
6,369,715, Peters U.S. Pat. No. 6,967,589, and the referenced
Honeywell, Inc. publication entitled "XYRS000 Series Wireless
Transmitters", it is indeed frequent practice to operate a
low-power RF transceiver or low-power RF transmitter and its RF
antenna at an intrinsically safe power level incapable of causing
an ignition in the hazardous location and then installing a
high-power RF transceiver and its RF antenna a short distance away
to relay the wireless communication data to a further distance.
However, additional components of an explosion-proof enclosure,
conduit seals, RF transceivers, RF transmitters, and RF antennas to
function as radio repeaters to increase distance is expensive and
makes the installation process more difficult and increases
probability of system failure. The present invention allows
placement of the high-power RF transceiver and one or more RF
antennas directly in the hazardous location, thereby enabling
longer distance wireless communication than the related arts using
less system components, thereby decreasing the probability for
system-level failures caused by lower-level faults at the
components and conduit connections.
[0029] As shown in the related art Dungan U.S. Pat. No. 6,794,991,
Pepperling U.S. Pat. No. 6,894,659, Rasmussen U.S. Pat. No.
7,014,502, Willoughby U.S. Pat. No. 7,057,577, the referenced Titan
Industries, Inc. publication entitled "CK-485MX Wireless
Transceiver", the referenced Titan Industries, Inc. publication
entitled "RTU System Radio Installation", and the referenced
Detcon, Inc. publication entitled "Detcon's Model Series 700,
Environmentally Bulletproof, Gas Detection Sensors" it is indeed
frequent practice to locate RF transceivers inside explosion-proof
enclosures and locate the RF antenna externally to the enclosure
for better reception. However, explosion-proof enclosures, multiple
conduit seals, special antennas, and special antenna connectors are
expensive and make the installation process more difficult and less
safe. The present invention is a complete explosion-proof,
self-contained wireless communication device with built-in system
components including an RF transceiver, one or more RF antennas,
and a conduit seal thus making installation safer by reducing the
need for the separate system components and the required conduit
connections and seals between the separate components.
[0030] Thus, there is a need for an explosion-proof wireless
communication apparatus with internal antenna system and
factory-installed sealed conduit port for use in hazardous location
to simplify installation efforts, reduce system components count,
and allow better wireless distance performance, whereby providing a
more reliable and safer wireless communication system for hazardous
location use.
[0031] The integration of a RF transceiver, one or more RF
antennas, and sealed conduit port in a single explosion-proof
wireless communication device as done in the present invention is
unique, provides challenges to the device designers in achieving
optimal antenna system performance, is novel and not obvious to
those skilled in the art as shown in the referenced related arts,
and has many utility advantages over the recently patented prior
related arts attempting to address similar problems.
BRIEF SUMMARY OF THE INVENTION
[0032] Electrical devices mounted in hazardous locations are
generally required to be in an explosion-proof enclosure or be
classified as intrinsically safe. By mounting electrical devices in
explosion-proof enclosures, the likelihood of an explosion caused
by electrical arching, such as opening and closing of a contact or
non-sealed relay device, are significantly reduced. An
explosion-proof enclosure is not necessary if the electrical device
is classified as intrinsically safe, which generally means the
circuits of the device are of such low power that they are
incapable of causing ignition. However, performance of many
electrical devices is degraded when power is limited and the lack
of performance must be compensated with installation of additional
system components elsewhere.
[0033] As shown in the related art, it is indeed frequent practice
to operate a low-power RF transceiver or low-power RF transmitter
and its RF antenna at an intrinsically safe power level incapable
of causing an ignition in the hazardous location and then
installing a high-power RF transceiver and its RF antenna a short
distance away to relay the wireless communication data to a further
distance. However, additional components of an explosion-proof
enclosure, conduit seals, RF transceivers, RF transmitters, and RF
antennas to function as radio repeaters to increase distance is
expensive and makes the installation process more difficult and
increases probability of system failure. The present invention
invention allows placement of the non-intrinsically safe RF
transceiver and one or more RF antennas directly in the hazardous
location, thereby enabling longer distance wireless communication
than the related arts using less system components, thereby
decreasing the probability for system-level failures caused by
lower-level faults at the components and conduit connections.
[0034] As shown in the related art, it is indeed frequent practice
to locate RF transceivers inside explosion-proof enclosures and
locate the RF antenna externally to the enclosure for better
reception. However, explosion-proof enclosures, multiple conduit
seals, special antennas, and special antenna connectors are
expensive and make the installation process more difficult and less
safe. The present invention is a complete explosion-proof,
self-contained wireless communication device with built-in system
components including an RF transceiver, one or more RF antennas,
and a conduit seal thus making installation safer by reducing the
need for the separate system components and the required conduit
connections and seals between the separate components.
[0035] The present invention is a self-contained RF wireless
communication device that provides data communications between two
or more devices for the supervisory control and/or data acquisition
of actuators, sensors, transducers, gas detectors, and other
devices located in explosive hazardous locations without the need
of installing explosion-proof enclosures, one or more external
antennas, one or more antenna connectors, excessive conduit
connections and seals, and the like, whereby reducing system
installation components count and eliminating conduit connections,
furthermore reducing the probability of system-level failures
caused by lower-level faults of components and conduit connections,
resulting in a less expensive and safer electrical equipment
installation.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0036] The accompanying figures, where like reference numerals
refer to identical or functionally similar elements throughout the
separate views and which together with the detailed description
below, are incorporated in and form part of the specification,
serve to further illustrate various embodiments and to explain
various principles and advantages all in accordance with the
present invention.
[0037] FIG. 1 is a view of one embodiment of a wireless
communication device.
[0038] FIG. 1B is a view of a second embodiment of a wireless
communication device.
[0039] FIG. 2 is an end view of the wireless communication device
of FIG. 1.
[0040] FIG. 2B is an end view of the wireless communication device
of FIG. 1B.
[0041] FIG. 3 is a cross sectional view of the wireless
communication device of FIG. 1.
[0042] FIG. 3B is a cross sectional view of the wireless
communication device of FIG. 1B.
[0043] FIG. 4 is a view of a third embodiment of a wireless
communication device.
[0044] FIG. 5 is an end view of the wireless communication device
of FIG. 4.
[0045] FIG. 6 is a cross sectional view of the wireless
communication device of FIG. 4.
[0046] FIG. 7 is a view of a forth embodiment of a wireless
communication device.
[0047] FIG. 8 is an end view of the wireless communication device
of FIG. 7.
[0048] FIG. 9 is a cross sectional view of the wireless
communication device of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
[0049] As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention, which
can be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure. Further, the terms and phrases
used herein are not intended to be limiting; but rather, to provide
an understandable description of the invention.
[0050] The terms a or an, as used herein, are defined as one or
more than one. The term plurality, as used herein, is defined as
two or more than two. The term another, as used herein, is defined
as at least a second or more. The terms including and/or having, as
used herein, are defined as comprising (i.e., open language). The
term coupled, as used herein, is defined as connected, although not
necessarily directly, and not necessarily electrically or
mechanically. The terms program, software application, and the like
as used herein, are defined as a sequence of instructions designed
for execution on a computer system, or programmable controller, or
the like. A program, computer program, or software application may
include a subroutine, a function, a procedure, an object method, an
object implementation, an executable application, an applet, a
source code, an object code, a shared library/dynamic load library
and/or other sequence of instructions are designed for execution on
a computer system, or programmable controller, or the like.
[0051] Explosion-proof housings for use in hazardous locations are
defined as housings that significantly reduce the likelihood of an
explosion caused by electrical arching, more particularly a housing
which is capable of: 1) withstanding an internal explosion of a
specified gas or vapor-in-air atmosphere; 2) preventing the
ignition of a specified gas or vapor-in-air atmosphere surrounding
housing due to sparks, flashes or internal explosion; and 3)
operating at temperatures which will not ignite the surrounding
atmosphere.
[0052] A capsule is defined as a form of housing or enclosure that
is generally small and compact. A capsule typically is a housing of
minimal size to enclose only a specific system to were the internal
free space is minimized. The shape and size of the capsule will
vary to enclose the system and meet other structural requirements.
For the present invention, the capsule walls are defined as
comprising: the perimeter walls enclosing the capsule internal
region, the sealed ports enclosing the capsule internal region, and
any open ports or joint gaps in the perimeter walls enclosing the
capsule internal region.
[0053] Encapsulated enclosure casting compound is defined as a
compound used to partially encapsulate a component, conductor,
and/or system while also serving as part of an enclosure wall.
[0054] Intrinsically safe circuits for use in hazardous locations
are defined as circuits which are incapable of causing ignition,
more particularly a circuit in which a spark or thermal effect,
produced either normally or in specified fault conditions, is
incapable under certain conditions of causing ignition of a mixture
of flammable or combustible material in air in the mixture's most
easily ignited concentration.
[0055] Electrical devices in an explosion-proof housing typically
couple to, operate, or take inputs from devices external to the
explosion-proof housing. Generally speaking, this communication
with the outside world takes place through electrical conductors
coupled to the external devices. These electrical conductors reach
the explosion-proof enclosures through electrical rigid metal
conduits.
[0056] Electrical conduit connections in hazardous locations have
conduit seals that generally have a sealing compound to literally
seal the conduit and wire/cable contained therein at that location,
whereby preventing harmful fluids and vapors traveling in the
conduit past that sealed point. In particular, the conduit sealing
compound forms a seal around each electrical conductor and with the
internal diameter of the conduit. This conduit seal restricts the
passage of gases, vapors and/or flames through the conduit.
[0057] A wireless modem is defined as a device that enables a
computer or electronic device to transmit data over a private
wireless data network or a wireless telephone system, or the like.
Computer and electronic device data is stored in digital form,
whereas data transmitted by RF wireless communication is
transmitted in the form of electromagnetic radio waves. A wireless
modem converts between the stored digital data form and the
transmitted radio wave data form. Examples of wireless modem
products are a IEEE 802.11b WiFi wireless LAN network card and a
GSM (Global System for Mobile Communication) wireless modem for
laptop computers.
[0058] Antenna resonator is define as an active antenna element. An
antenna ground plane is defined as an antenna grounding structure.
The term "antenna" by itself is defined as an active antenna
element referenced to a common antenna grounding structure.
[0059] Multiple antenna diversity is defined as a method intended
to overcome frequency interference and a fading phenomenon due to a
multi-path phenomenon of a radio wave signal in a wireless
propagation environment. A multiple antenna diversity system allows
multiple frequency bands of operation and forms multiple radio
signal paths un-correlated with each other on space and/or on
antenna polarization through multiple antennas, and then receives a
signal through the minimum interfered or minimum fading signal path
to optimize antenna system performance. Many existing wireless
communication systems widely used in an indoor environment where
frequency interference and fading phenomenon is serious, such as a
wireless LAN, use such a defined multiple antenna diversity system
to select between different frequency bands and physical antenna
resonators to optimize antenna system performance.
[0060] The concept of the present invention can be advantageously
used on any electronic device requiring a wireless modem capable of
transmission and/or reception of RF data signals. The wireless
modem portion (350, 650, 950) of the invention may be constructed
in accordance with a digital communication standard or an analog
communication standard, whereby allowing wireless data
communication via a switched telephone network or private wireless
data network. The wireless modem portion (350, 650, 950) generally
includes an RF transceiver, at least one antenna resonator, a
frequency synthesizer, modulator, demodulator, a signal processor,
data converter circuitry, and a serial data UART for interfacing to
a computer, electronic device, or the like. The wireless modem
electronics typically incorporated into an IEEE 802.11b WiFi
wireless network card, GSM cellular wireless modem, SCADA two-way
radio, or the like are well known in the art, and can be
incorporated into the wireless communication device of the present
invention.
[0061] The data converter portion being defined as either a
non-intrinsically safe data converter portion or an intrinsically
safe data converter portion of the invention allows conducted
electrical data communication with external electronic devices and
may be constructed in accordance with a digital communication
standard or an analog communication standard or an I/O protection
circuit or simple voltage divider, whereby allowing data
communication via methods including serial data communication and
analog communication, such as RS-232, RS-485, and 4-20 mA analog
current loop used on devices such as gas detectors, gas sensors,
pressure sensors, flow valves, solenoid actuated valves, and alarm
control panels. The data converter portion generally can include
I/O circuit protection, voltage level conditioner circuitry,
threshold comparator, A/D converter, D/A converter, driver
circuitry, a programmable controller, and a serial data UART for
data communication interfacing. The data signal converter
electronics typically incorporated into a RS-485 serial converter
product, 4-20 mA current loop transceiver product, gas detector,
pressure gauge, analog input sensor, acoustic sensor, shutoff valve
controller, or the like are well known in the art, and can be
incorporated into the wireless communication device of the present
invention.
[0062] The intrinsically safe data converter portion of the
invention further allows safe conducted electrical data
communication with external electronic devices and may be
constructed in accordance with a digital signal standard or an
analog signal standard or an I/O protection circuit or simple
voltage divider, whereby allowing safe data transfer in hazardous
locations via methods including serial data communication, analog
communication, and analog signal sampling, such as RS-232, RS-485,
4-20 mA analog current loop, synchronous serial data, and 0-10 volt
analog transducer signals used on devices such as video cameras,
microphones, speakers, piezoelectric devices, electrochemical
sensors, gas detectors, gas sensor transducers, pressure sensor
transducers, acoustic transducers, flow meters, and shutoff
solenoid valves. The intrinsically safe data converter portion
generally can include intrinsically safe barrier devices, I/O
circuit protection, a voltage level conditioner circuit, threshold
comparator, A/D converter, D/A converter, driver circuit, a
programmable controller, and a serial data UART for data
communication interfacing. The intrinsically safe data converter
electronics typically incorporated into a RS-485 serial converter
product, 420 mA analog current loop transceiver product, gas
detector, pressure gauge, analog input sensor, acoustic sensor,
shutoff valve controller, or the like are well known in the art,
and can be incorporated into the wireless communication device of
the present invention. The intrinsically safe data converter
portion provides an intrinsically safe barrier method to prevent an
ignition at its interface to the explosive atmosphere hazardous
location, whereby making it an intrinsically safe circuit, as
previously defined herein.
[0063] The power supply portion being defined as either a
non-intrinsically safe power supply portion or an intrinsically
safe power supply portion may be constructed in accordance with an
I/O protection circuit, simple voltage divider, standard linear
regulator, a switching AC-to-DC power supply, a DC-to-DC power
supply design, or a battery circuit. The intrinsically safe and
non-intrinsically safe power supply portions generally can include
I/O circuit protection, linear regulators, storage capacitors,
inductors, diodes, batteries, and controller integrated circuits.
The intrinsically safe and non-intrinsically safe power supplies
typically incorporated in electronic devices and devices used in
hazardous environments such as gas detectors, pressure sensors,
shutoff valve controllers, or the like are well known in the art,
and can be incorporated into the communication device of the
present invention. The intrinsically safe power supply portion
provides an intrinsically safe barrier method to prevent an
ignition at its interface to the explosive atmosphere hazardous
location, whereby making it an intrinsically safe circuit, as
previously defined herein.
[0064] The illustrated wireless communication device 100 in FIG. 1,
by way of example only, is one preferred embodiment of a wireless
communication device, in accordance with the present invention,
having a conventional wireless modem circuitry, data converter
circuitry, and power supply circuitry, as is known in the art, and
will not be presented here for simplicity. Although the invention
is illustrated herein with reference to a wireless communication
device for hazardous locations, the invention is alternatively
applied to other applications such as, for example, supervisory
control and data acquisition of devices in non-hazardous locations
like residential, commercial, and industrial security systems with
electrochemical sensors, radiated energy sensors, and solenoid
actuators.
[0065] The wireless communication device 100, as illustrated,
includes a capsule 110 for covering, protecting and supporting the
internal components encased within, along with providing mechanical
structure for interfacing to external devices. By way of example,
the preferred embodiment of the present invention is described in
relation to a fixed housing such as the capsule 110 of FIG. 1;
however, it will be appreciated by one of ordinary skill in the art
that the present invention is similarly applicable to a housing of
different shape and length to incorporate different electronic
circuitry and/or different internal antenna systems that may vary
in size due to number of spatially separated antenna resonators,
frequency of operation, radiation pattern, polarization, and
characteristic impedance.
[0066] In accordance with the present invention, the capsule 110
comprises a conduit fitting portion 120 and a non-metallic portion
130. The non-metallic portion 130, for example, can be manufactured
by a plastic injection molding technique as is well known in the
art. The conduit fitting portion 120 is preferably made of a
material to provide the capsule 110 a rigid metal conduit
mechanical interface structure with more strength than housing
comprised totally of the non-metallic portion 130 material so that
the conduit port 180 will be in accordance with Article 501 in the
National Electric Code ("NEC") ANSI/NFPA 70-2005. The conduit
fitting portion 120, for example, can be manufactured using any
material which from a mechanical point of view is any physical
element showing very high tensile strength. Such materials include
iron, aluminum, stainless steel, or a non-metallic material with
similar strength to achieve the same result. The conduit fitting
portion 120 provides strength and rigidity over a non-metallic
material, such as glass reinforced plastic, used for the
non-metallic portion 130. While one could attempt to integrate the
conduit fitting portion 120 with the non-metallic portion 130 to
create an integrated single piece housing and manufacture the
integrated housing out of a high-grade non-metallic material in
order to design around or improve the patent, the insubstantial
change to an integrated single piece housing would in effect be
deemed equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0067] In accordance with the present invention, the capsule 110
comprises one non-metallic portion 130 and one conduit fitting
portion 120. While one could attempt to break the non-metallic
portion 130 into two portions comprising a non-metallic portion for
housing the antenna system, whereby allowing radio wave
penetration, and another portion of non-metallic or metallic
material, whereby attempting to design around or improve the
patent, the insubstantial change in dividing the non-metallic
portion 130 to multiple portions would in effect be deemed
equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0068] FIG. 2 is an end view of the wireless communication device
100 of FIG. 1, looking at the conduit port 180.
[0069] FIG. 3 is a cross sectional view of the wireless
communication device 100 of FIG. 1. As illustrated, the
communication device 100 includes the capsule 110 and a plurality
of internal components. The capsule 110 encases the plurality of
internal components, providing covering, protection, and interface
port mechanical structural support. The plurality of internal
components, for example, can include an RF transceiver 345, (or
alternatively a separate RF transmitter and RF receiver (not
shown)), interface lead wires 386 serving as a plurality of conduit
port electrical conductors, a power supply portion 384, a data
converter portion 383, and the like. The plurality of internal
components, in accordance with the present invention, preferably
further includes an antenna RF switch 352, an antenna resonator
351, and an antenna grounding structure 353. The plurality of
internal components further can comprise, as described previously
herein for functionality, of I/O circuit protection, programmable
controllers, a frequency synthesizer, a signal processor, serial
data UART devices, voltage level conditioner circuits, threshold
comparators, A/D converters, D/A converters, driver circuits,
linear regulators, storage capacitors, inductors, diodes, switch
mode controller integrated circuit, and the like. A printed circuit
board 340 provides conducted electrical connection and mechanical
structure between the plurality of internal components within the
wireless communication device 100 as illustrated.
[0070] In accordance with the present invention, the capsule 110
comprises one non-metallic portion 130 and one conduit fitting
portion 120 joined together by assembly of two mating threaded
sections to make the threaded joint 321. While one could attempt to
use a rabbet joint, straight or flat joint, labyrinth joint, or the
like instead of the threaded joint 321 as specified in the present
embodiment, whereby attempting to design around or improve the
patent, the insubstantial change to a different type of mating
joint would in effect be deemed equivalent to the present invention
since it would perform substantially the same function, in
substantially the same way, to yield substantially the same
result.
[0071] In accordance with the present invention, an antenna system
for the wireless communication device 100 comprises the antenna
resonator 351, the antenna RF switch 352, and the antenna grounding
structure 353. The antenna resonator 351 and the antenna grounding
structure 353 can be built in different ways and using different
technologies as is well known in the art. For example, the antenna
resonator 351 can be a helix-whip coupled to quarter-wave image
grounding structure, a meandered encapsulated flexible circuit, a
meandered none encapsulated flexible circuit, one or more meandered
wires, any combination of active and parasitic radiators, and the
like. The antenna system functions using the combination of all the
mechanical parts that constitute the antenna system and its
switches necessary to carry the RF signal from and towards the RF
transceiver 345 including the antenna resonator 351, the antenna RF
switch 352, coupled between the antenna resonator 351 and the RF
transceiver 345. The antenna system is for radiating and collecting
radio wave energy and is coupled and matched with circuitry within
the plurality of internal components such as the RF switch 352 as
is known in the art.
[0072] As illustrated, the antenna resonator 351 of the antenna
system is located within the non-metallic portion 130 of the
capsule 110 in accordance with the present invention. Locating the
antenna resonator 351, the antenna RF switch 352, and the antenna
grounding structure 353 within the non-metallic portion 130
decreases the probability of the antenna system being shielded or
detuned from the impedance of interest, thereby providing
consistent overall antenna system performance efficiency. While one
could attempt to use a conduit fitting portion 120 made of metal as
a portion of the antenna resonator 351 or a portion of the antenna
grounding structure 353 instead of locating them entirely in the
non-metallic portion as specified in the present invention, whereby
attempting to design around or improve the patent, the
insubstantial change to the antenna system would in effect be
deemed equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0073] As illustrated in FIG. 3, the wireless communication device
100 includes a conduit port 180 for electromechanical interfacing
to a rigid metal electrical conduit connection system or to an
electrical enclosure, junction box, or the like. The conduit
fitting portion 180 has within a conduit sealing compound 382 to
incorporate a factory-installed conduit seal, as previously
described herein. The factory-installed conduit seal is specified
to withstand a minimum 600 PSIG hydrostatic pressure test applied
at the conduit port 180, whereby the conduit fitting portion 120,
conduit port threaded portion 385, and the conduit sealing compound
382 are designed to withstand the force of an explosion,
eliminating the need for a separate conduit seal at the point where
the device connects to an electrical conduit, an electrical
enclosure, or the like. The interface lead wires protruding out the
conduit port 180, and having the conduit sealing compound 382
forming a seal around each electrical conductor, provide conducted
electrical coupling to the power supply portion 384 and the data
converter portion 383.
[0074] In accordance with the present invention, the conduit port
180 has within a conduit sealing compound 382 to incorporate a
factory-installed conduit seal, as previously defined herein. While
one could attempt to remove the conduit sealing compound 382 in
order to design around or improve the patent, the insubstantial
change would in effect be deemed equivalent since an external
conduit seal must then be installed and the wireless communications
device would perform substantially the same function, in
substantially the same way, to yield substantially the same
result.
[0075] As illustrated in FIG. 3, a conduit sealing compound barrier
381 prevents the conduit sealing compound 382 from entering the
wireless modem cavity 341. While one could attempt to remove the
conduit sealing compound barrier 381 and fill the wireless modem
cavity 341 with a sealing compound or potting material in order to
design around or improve the patent, the insubstantial change would
in effect be deemed equivalent since it would perform substantially
the same function, in substantially the same way, to yield
substantially the same result.
[0076] In accordance with the present invention, the conduit port
threaded portion 385 is specified as an external thread on the
first end of the conduit fitting portion 120 for interfacing to a
rigid metal conduit connection system, or the like. While one could
attempt to use an internal thead for the conduit port theaded
portion 385 instead of an external thread as specified in the
present invention, whereby attempting to design around or improve
the patent, the insubstantial change to the different gender thread
would in effect be deemed equivalent to the present invention since
it would perform substantially the same function, in substantially
the same way, to yield substantially the same result.
[0077] FIG. 3 further illustrates one embodiment of the wireless
modem portion 350 for use within the wireless communication device
100 in accordance with the present invention and the relationship
of the various portions of the wireless modem portion 350 with the
various portions of the housing 110. As illustrated, the wireless
modem portion 350, in accordance with a preferred embodiment of the
present invention, comprises a printed circuit board 340 and
associated internal components connected therein preferably housed
within the non-metallic portion 130 of the capsule 110 as
previously described herein. The wireless modem 350 further
preferably comprises an antenna system contained within the
non-metallic portion 130 of the capsule 110. It will further be
appreciated by those of ordinary skill in the art that the wireless
modem 350 can be utilized for all communication protocols such as
FHSS (Frequency Hopping Spread Spectrum), DSSS (Direct Sequence
Spread Spectrum), DTS (Digital Modulation Spectrum), WLAN (Wireless
Local Area Network), TDMA (time division multiple access), CDMA
(Code Division Multiple Access), GSM (Global System for Mobile
Communication), and the like. It will be further appreciated that
the wireless modem 350 can be utilized for data transmit and
receive such as operating with GPRS (General Packet Radio Service),
EDGE (An edge device is a physical device that can pass packets
between a legacy type of network such as an Ethernet network and an
ATM network, using Data Link layer and Network layer information),
3G (third-generation wireless) for facilitating the use of wireless
data transfer, Internet access, and the like.
[0078] In accordance with the present invention, the interface lead
wires 386 protruding from the conduit port 180 are coupled to the
power supply portion 384, whereby providing a means for the power
supply portion 384 to receive electrical power from an external
source connected to the conduit port 180. The power supply portion
384 is coupled to the data converter portion 383 and the wireless
modem portion 350, whereby the power supply portion 384 is capable
of providing electrical power to the data converter portion 383 and
the wireless modem portion 350.
[0079] In accordance with the present invention, the interface lead
wires 386 protruding from the conduit port 180 are coupled to the
data converter portion 383, whereby providing a means for the data
converter portion 383 to transfer data with an external electronic
device connected to the conduit port 180. The non-intrinsically
safe data converter portion 383 is coupled to the wireless modem
portion 350, whereby providing wireless communication ability for
an external electronic device connected to the conduit port
180.
[0080] The illustrated wireless communication device 101 in FIG.
1B, by way of example only, is another preferred embodiment of a
wireless communication device, in accordance with the present
invention, having a conventional wireless modem circuitry, data
converter circuitry, and power supply circuitry, as is known in the
art, and will not be presented here for simplicity. Although the
invention is illustrated herein with reference to a wireless
communication device for hazardous locations, the invention is
alternatively applied to other applications such as, for example,
supervisory control and data acquisition of devices in
non-hazardous locations like residential, commercial, and
industrial security systems with electrochemical sensors, radiated
energy sensors, and solenoid actuators.
[0081] The wireless communication device 101, as illustrated,
includes a capsule 131 for covering, protecting and supporting the
internal components encased within, along with a potting compound
201 to seal the open end of the capsule. By way of example, the
preferred embodiment of the present invention is described in
relation to a fixed housing such as the capsule 131 of FIG. 1B;
however, it will be appreciated by one of ordinary skill in the art
that the present invention is similarly applicable to a housing of
different shape and length to incorporate different electronic
circuitry and/or different internal antenna systems that may vary
in size due to number of spatially separated antenna resonators,
frequency of operation, radiation pattern, polarization, and
characteristic impedance.
[0082] In accordance with the present invention, the capsule 131
comprises one non-metallic portion. While one could attempt to
break the non-metallic portion into two portions comprising a
non-metallic portion for housing the antenna system, whereby
allowing radio wave penetration, and another portion of
non-metallic or metallic material, whereby attempting to design
around or improve the patent, the insubstantial change in dividing
the non-metallic portion to multiple portions would in effect be
deemed equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0083] FIG. 2B is an end view of the wireless communication device
101 of FIG. 1B, looking at the end with potting compound.
[0084] FIG. 3B is a cross sectional view of the wireless
communication device 101 of FIG. 1B. As illustrated, the
communication device 101 includes the capsule 131 and a plurality
of internal components. The capsule 131 encases the plurality of
internal components, providing covering, and protection. The
plurality of internal components, for example, can include an RF
transceiver 345, (or alternatively a separate RF transmitter and RF
receiver (not shown)), a power supply portion 384, a data converter
portion 383, and the like. The transducer 322 may be a temperature
transducer, pressure transducer, or the like. A portion of the
transducer 322 may extend to the exterior of the capsule for proper
operation. The plurality of internal components, in accordance with
the present invention, preferably further includes an antenna RF
switch 352, an antenna resonator 351, and an antenna grounding
structure 353. The plurality of internal components further can
comprise, as described previously herein for functionality, of I/O
circuit protection, programmable controllers, a frequency
synthesizer, a signal processor, serial data UART devices, voltage
level conditioner circuits, threshold comparators, A/D converters,
D/A converters, driver circuits, linear regulators, storage
capacitors, inductors, diodes, switch mode controller integrated
circuit, and the like. A printed circuit board 340 provides
conducted electrical connection and mechanical structure between
the plurality of internal components within the wireless
communication device 101 as illustrated.
[0085] FIG. 3B further illustrates one embodiment of the wireless
modem portion 350 for use within the wireless communication device
101 in accordance with the present invention and the relationship
of the various portions of the wireless modem portion 350 with the
various portions of the capsule 131. As illustrated, the wireless
modem portion 350, in accordance with a preferred embodiment of the
present invention, comprises a printed circuit board 340 and
associated internal components connected therein preferably housed
within non-metallic capsule 131 as previously described herein. The
wireless modem 350 further preferably comprises an antenna system
contained within the non-metallic capsule 131. It will further be
appreciated by those of ordinary skill in the art that the wireless
modem 350 can be utilized for all communication protocols such as
FHSS (Frequency Hopping Spread Spectrum), DSSS (Direct Sequence
Spread Spectrum), DTS (Digital Modulation Spectrum), WLAN (Wireless
Local Area Network), TDMA (time division multiple access), CDMA
(Code Division Multiple Access), GSM (Global System for Mobile
Communication), and the like. It will be further appreciated that
the wireless modem 350 can be utilized for data transmit and
receive such as operating with GPRS (General Packet Radio Service),
EDGE (An edge device is a physical device that can pass packets
between a legacy type of network such as an Ethernet network and an
ATM network, using Data Link layer and Network layer information),
3G (third-generation wireless) for facilitating the use of wireless
data transfer, Internet access, and the like.
[0086] The illustrated wireless communication device 400 in FIG. 4,
by way of example only, is another preferred embodiment of a
wireless communication device, in accordance with the present
invention, having a conventional wireless modem circuitry, data
converter circuitry, and power supply circuitry, as is known in the
art, and will not be presented here for simplicity. Although the
invention is illustrated herein with reference to a wireless
communication device for hazardous locations, the invention is
alternatively applied to other applications such as, for example,
supervisory control and data acquisition of devices in
non-hazardous locations like residential, commercial, and
industrial security systems with electrochemical sensors, radiated
energy sensors, and solenoid actuators.
[0087] The wireless communication device 400, as illustrated,
includes a capsule 410 for covering, protecting and supporting the
internal components encased within, along with providing mechanical
structure for interfacing to external devices, transducers,
sensors, and the like. By way of example, the preferred embodiment
of the present invention is described in relation to a fixed
housing such as the capsule 410 of FIG. 4; however, it will be
appreciated by one of ordinary skill in the art that the present
invention is similarly applicable to a housing of different shape
and length to incorporate different electronic circuitry and/or
different internal antenna systems that may vary in size due to
number of spatially separated antenna resonators, frequency of
operation, radiation pattern, polarization, and characteristic
impedance.
[0088] In accordance with the present invention, the capsule 410
comprises a conduit fitting portion 420 and a non-metallic portion
430. The non-metallic portion 430, for example, can be manufactured
by a plastic injection molding technique as is well known in the
art. The conduit fitting portion 420 is preferably made of a
material to provide the capsule 410 a rigid metal conduit
mechanical interface structure with more strength than a housing
comprised totally of the non-metallic portion 430 material so that
the conduit port 480 will be in accordance with Article 501 in the
National Electric Code ("NEC") ANSI/NFPA 70-2005. The conduit
fitting portion 420, for example, can be manufactured using any
material which from a mechanical point of view is any physical
element showing very high tensile strength. Such materials include
iron, aluminum, stainless steel, or a non-metallic material with
similar strength to achieve the same result. The conduit fitting
portion 420 provides strength and rigidity over a non-metallic
material, such as glass reinforced plastic, used for the
non-metallic portion 430. While one could attempt to integrate the
conduit fitting portion 420 with the non-metallic portion 430 to
create an integrated single piece housing and manufacture the
integrated housing out of a high-grade non-metallic material in
order to design around or improve the patent, the insubstantial
change to an integrated single piece housing would in effect be
deemed equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0089] In accordance with the present invention, the capsule 410
comprises one non-metallic portion 430 and one conduit fitting
portion 420. While one could attempt to break the non-metallic
portion 430 into two portions comprising a non-metallic portion for
housing the antenna system, whereby allowing radio wave
penetration, and another portion of non-metallic or metallic
material, whereby attempting to design around or improve the
patent, the insubstantial change in dividing the non-metallic
portion 430 to multiple portions would in effect be deemed
equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0090] FIG. 5 is an end view of the wireless communication device
400 of FIG. 4, looking at the intrinsically safe circuit interface
port 470.
[0091] FIG. 6 is a cross sectional view of the wireless
communication device 400 of FIG. 4. As illustrated, the
communication device 400 includes the capsule 410 and a plurality
of internal components. The capsule 410 encases the plurality of
internal components, providing covering, protection, and interface
port mechanical structural support. The plurality of internal
components, for example, can include an RF transceiver 645, (or
alternatively a separate RF transmitter and RF receiver (not
shown)), interface lead wires serving as a plurality of conduit
port electrical conductors 686, a power supply portion 684, a data
converter portion 683, a plurality of intrinsically safe interface
port electrical conductors 676, an intrinsically safe power supply
portion 674, an intrinsically safe data converter portion 673, and
the like. The plurality of internal components, in accordance with
the present invention, preferably further includes a first antenna
RF switch 652, a second antenna RF switch 656, a first antenna
resonator 651, a second antenna resonator 654, a third antenna
resonator 655, a forth antenna resonator 657, and an antenna
grounding structure 653. The plurality of internal components
further can comprise, as described previously herein for
functionality, of I/O circuit protection, programmable controllers,
a frequency synthesizer, a signal processor, serial data UART
devices, voltage level conditioner circuits, threshold comparators,
A/D converters, D/A converters, driver circuits, linear regulators,
storage capacitors, inductors, diodes, switch mode controller
integrated circuit, and the like. A printed circuit board 640
provides conducted electrical connection and mechanical structure
between the plurality of internal components within the wireless
communication device 400 as illustrated.
[0092] In accordance with the present invention, the capsule 410
comprises one non-metallic portion 430 and one conduit fitting
portion 420 joined together by assembly of two mating threaded
sections to make the threaded joint 621. While one could attempt to
use a rabbet joint, straight or flat joint, labyrinth joint, or the
like instead of the theaded joint 621 as specified in the present
embodiment, whereby attempting to design around or improve the
patent, the insubstantial change to a different type of mating
joint would in effect be deemed equivalent to the present invention
since it would perform substantially the same function, in
substantially the same way, to yield substantially the same
result.
[0093] In accordance with the present invention, an antenna system
for the wireless communication device 400 using a multiple antenna
diversity method, comprises a first antenna resonator 651, a second
antenna resonator 654, a third antenna resonator 655, a forth
antenna resonator 657, a first antenna RF switch 652, a second
antenna RF switch 656, and an antenna grounding structure 653. The
antenna resonators and the antenna grounding structure referred
herein can be built in different ways and using different
technologies as is well known in the art. For example, an antenna
resonator can be a helix-whip coupled to quarter-wave image
grounding structure, a meandered encapsulated flexible circuit, a
meandered none encapsulated flexible circuit, one or more meandered
wires, any combination of active and parasitic radiators, and the
like. The antenna system functions using the combination of all the
mechanical parts that constitute the antenna system and its
switches necessary to carry the RF signal from and towards the RF
transceiver 645 including for example the first antenna resonator
651, the first antenna RF switch 652, coupled between the first
antenna resonator 651 and the RF transceiver 645. The antenna
system is for radiating and collecting radio wave energy and is
coupled and matched to the RF transceiver 645 with circuitry within
the plurality of internal components such as the first antenna RF
switch 652 as is known in the art.
[0094] As illustrated, the antenna system is located within the
non-metallic portion 430 of the capsule 410 in accordance with the
present invention. Locating the plurality of antenna resonators,
the antenna RF switches, and the antenna grounding structure within
the non-metallic portion 430 decreases the probability of the
antenna system being shielded or detuned from the impedance of
interest, thereby providing consistent overall antenna system
performance efficiency. While one could attempt to use a conduit
fitting portion 420 made of metal as a portion of the antenna
resonators or a portion of the antenna grounding structure instead
of locating them entirely in the non-metallic portion as specified
in the present invention, whereby attempting to design around or
improve the patent, the insubstantial change to the antenna system
would in effect be deemed equivalent to the present invention since
it would perform substantially the same function, in substantially
the same way, to yield substantially the same result.
[0095] As illustrated in FIG. 6, the wireless communication device
400 includes a conduit port 480 for electromechanical interfacing
to a rigid metal electrical conduit connection system or to an
electrical enclosure, junction box, or the like. The conduit
fitting portion 480 has within a conduit sealing compound 682 to
incorporate a factory-installed conduit seal, as previously defined
herein. The factory-installed conduit seal is specified to
withstand a minimum 600 PSIG hydrostatic pressure test applied at
the conduit port 480, whereby the conduit fitting portion 420,
conduit port threaded portion 685, and the conduit sealing compound
682 are designed to withstand the force of an explosion,
eliminating the need for a separate conduit seal at the point where
the device connects to an electrical conduit, an electrical
enclosure, or the like. The interface lead wires protruding out the
conduit port 480, and having the conduit sealing compound 682
forming a seal around each electrical conductor, provide conducted
electrical coupling to the power supply portion 684 and the data
converter portion 683.
[0096] In accordance with the present invention, the conduit port
480 has within a conduit sealing compound 682 to incorporate a
factory-installed conduit seal, as previously defined herein. While
one could attempt to remove the conduit sealing compound 682 in
order to design around or improve the patent, the insubstantial
change would in effect be deemed equivalent since an external
conduit seal must then be installed and the wireless communications
device would perform substantially the same function, in
substantially the same way, to yield substantially the same
result.
[0097] As illustrated in FIG. 6, a conduit sealing compound barrier
681 prevents the conduit sealing compound 682 from entering the
wireless modem cavity 641. While one could attempt to remove the
conduit sealing compound barrier 681 and fill the wireless modem
cavity 641 with a sealing compound or potting material in order to
design around or improve the patent, the insubstantial change would
in effect be deemed equivalent since it would perform substantially
the same function, in substantially the same way, to yield
substantially the same result.
[0098] In accordance with the present invention, the conduit port
threaded portion 685 is specified as an external thread on the
first end of the conduit fitting portion 420 for interfacing to a
rigid metal conduit connection system, or the like. While one could
attempt to use an internal thread for the conduit port threaded
portion 685 instead of an external thread as specified in the
present invention, whereby attempting to design around or improve
the patent, the insubstantial change to the different gender thread
would in effect be deemed equivalent to the present invention since
it would perform substantially the same function, in substantially
the same way, to yield substantially the same result.
[0099] FIG. 6 further illustrates one embodiment of the wireless
modem portion 650 for use within the wireless communication device
400 in accordance with the present invention and the relationship
of the various portions of the wireless modem portion 650 with the
various portions of the capsule 410. As illustrated, the wireless
modem portion 650, in accordance with a preferred embodiment of the
present invention, comprises a printed circuit board 640 and
associated internal components connected therein preferably housed
within the non-metallic portion 430 of the capsule 410 as
previously described herein. The wireless modem 650 further
preferably comprises an antenna system contained within the
non-metallic portion 430 of the capsule 410. The antenna system,
for example, can use a multiple antenna diversity method of a
plurality of antennas comprising a first antenna resonator 651
designed for horizontal polarization, and/or a second antenna
resonator 654 designed for vertical polarization, and/or a third
antenna resonator 655 designed for an alternate frequency band,
and/or a forth antenna resonator 657 designed for spatial diversity
from the first antenna resonator 651. It will be appreciated by
those of ordinary skill in the art that the plurality of antennas
can include any count of one or more antenna resonators or
combination of antenna resonators designed to any combination of
polarizations, frequencies, and spatial diversities as desired in
accordance with the present invention. The antenna resonators
polarization and spatial diversity can include, for example,
vertical polarization, horizontal polarization, quarter wavelength
spatial diversity of the first horizontal polarized antenna,
quarter wavelength spatial diversity of the first vertical
polarized antenna, and the like. It will further be appreciated by
those of ordinary skill in the art that the wireless modem 650 and
its multiple antenna diversity system can be utilized for all
communication protocols such as FHSS (Frequency Hopping Spread
Spectrum), DSSS (Direct Sequence Spread Spectrum), DTS (Digital
Modulation Spectrum), WLAN (Wireless Local Area Network), TDMA
(time division multiple access), CDMA (Code Division Multiple
Access), GSM (Global System for Mobile Communication), and the
like. It will be further appreciated that the wireless modem 650
can be utilized for data transmit and receive such as operating
with GPRS (General Packet Radio Service), EDGE (An edge device is a
physical device that can pass packets between a legacy type of
network such as an Ethernet network and an ATM network, using Data
Link layer and Network layer information), 3G (third-generation
wireless) for facilitating the use of wireless data transfer,
Internet access, and the like.
[0100] As illustrated in FIG. 4, the wireless communication device
400 includes an intrinsically safe circuit interface port 470 for
electromechanical interfacing to an external device, external
transducer module 490, or the like. Such a transducer module 490
may be a camera, microphone, speaker, piezoelectric device,
electrochemical sensor, electromechanical transducer, analog output
transducer, digital output transducer, or the like, and may sense
gas, temperature, pressure, flow rate, vibration, torsion,
mechanical stress, liquid level, or other parameters of interest
which may be monitored periodically or otherwise on command. The
transducer module 490 could comprise of a transducer 692,
transducer module housing 691, transducer electrical conductors
693, and transducer mechanical connector 694. The transducer module
490 may electrically connect through a cable conductor to another
external device for supervisory control of devices such as control
relays, shutoff valves, or the like. The transducer module 490
coupled to the wireless communications device 400 through the
intrinsically safe circuit interface port 470 transmits and/or
receives analog or digital signal and power through the plurality
of intrinsically safe interface port electrical conductors 676.
[0101] In accordance with the present invention, the intrinsically
safe circuit interface port 470 is intrinsically safe for use in
hazardous locations, which is incapable of causing ignition. Thus,
the encapsulated enclosure casting compound 672 within the
intrinsically safe circuit interface port 470 and encapsulating the
plurality of intrinsically safe interface port electrical
conductors 676 provides electrical and mechanical isolation between
the surrounding explosive atmosphere of the capsule and the
ignition sources of the electronic system internal to the capsule.
The intrinsically safe circuit interface port mechanical connector
675 provides a mechanical interface for devices such as the
transducer module 490. The plurality of intrinsically safe
interface port electrical conductors 676 provide electrical
connection to the intrinsically safe power supply portion 674 and
the intrinsically safe data converter portion 673 for external
devices such as the transducer module 490, or the like.
[0102] As illustrated in FIG. 6, an encapsulated enclosure casting
compound barrier 681 prevents the encapsulated enclosure casting
compound 672 from entering the wireless modem cavity 641. While one
could attempt to remove the encapsulated enclosure casting compound
barrier 681 and fill the wireless modem cavity 641 with a sealing
compound or potting material in order to design around or improve
the patent, the insubstantial change would in effect be deemed
equivalent since it would perform substantially the same function,
in substantially the same way, to yield substantially the same
result.
[0103] In accordance with the present invention, the intrinsically
safe circuit interface port 470 comprises an intrinsically safe
circuit interface port mechanical connector 675 and a plurality of
intrinsically safe interface port electrical conductors 676 for
interfacing to external devices such as the transducer module 490,
or the like. By way of example, the preferred embodiment of the
present invention is described in relation to a threaded portion of
the housing as the intrinsically safe circuit interface port
mechanical connector 675 and described in relation to a socket
connector as the plurality of intrinsically safe interface port
electrical conductors 676; however, it will be appreciated by one
of ordinary skill in the art that the present invention is
similarly applicable to an external device, or transducer module
490, or the like, of different mechanical and electrical
interconnections to incorporate different devices or transducer
types that may vary in size and function.
[0104] In accordance with the present invention, the interface lead
wires 686 protruding from the conduit port 480 are coupled to the
power supply portion 684, whereby providing a means for the power
supply portion 684 to receive electrical power from an external
source connected to the conduit port 480. The power supply portion
684 is coupled to the data converter portion 683, the intrinsically
safe power supply portion 674, the intrinsically safe data
converter portion 673, and the wireless modem portion 650, whereby
the power supply portion 684 is capable of providing electrical
power to the data converter portion 683, the intrinsically safe
power supply portion 674, the intrinsically safe data converter
portion 673, and the wireless modem portion 650.
[0105] In accordance with the present invention, the interface lead
wires 686 protruding from the conduit port 480 are coupled to the
data converter portion 683, whereby providing a means for the data
converter portion 683 to transfer data with an external electronic
device connected to the conduit port 480. The data converter
portion 683 is coupled to the wireless modem portion 650, whereby
providing wireless data communication ability for an external
electronic device connected to the conduit port 480.
[0106] In accordance with the present invention, the plurality of
intrinsically safe interface port electrical conductors 676 are
coupled to the intrinsically safe data converter portion 673,
whereby providing a means for the intrinsically safe data converter
portion 673 to transfer data with an external electronic device, or
transducer module 490, or the like. The intrinsically safe data
converter portion 673 is coupled to the wireless modem portion 650,
whereby providing wireless data communication ability for an
external electronic device, or transducer module 490, or the like,
connected to the intrinsically safe circuit interface port 470.
[0107] In accordance with the present invention, the intrinsically
safe data converter portion 673 further preferably is coupled to
the data converter portion 683, whereby providing conducted
electrical data communication ability between an external
electronic device connected to the intrinsically safe circuit
interface port 470 and an external electronic device connected to
the conduit port 480.
[0108] The illustrated wireless communication device 700 in FIG. 7,
by way of example only, is another preferred embodiment of a
wireless communication device, in accordance with the present
invention, having a conventional wireless modem circuitry, data
converter circuitry, and power supply circuitry, as is known in the
art, and will not be presented here for simplicity. Although the
invention is illustrated herein with reference to a wireless
communication device for hazardous locations, the invention is
alternatively applied to other applications such as, for example,
supervisory control and data acquisition of devices in
non-hazardous locations like residential, commercial, and
industrial security systems with electrochemical sensors, radiated
energy sensors, and solenoid actuators.
[0109] The wireless communication device 700, as illustrated,
includes a capsule 710 for covering, protecting and supporting the
internal components encased within, along with providing mechanical
structure for interfacing to external devices, transducers,
sensors, and the like. By way of example, the preferred embodiment
of the present invention is described in relation to a fixed
housing such as the capsule 710 of FIG. 7; however, it will be
appreciated by one of ordinary skill in the art that the present
invention is similarly applicable to a housing of different shape
and length to incorporate different electronic circuitry and/or
different internal antenna systems that may vary in size due to
number of spatially separated antenna resonators, frequency of
operation, radiation pattern, polarization, and input
impedance.
[0110] In accordance with the present invention, the capsule 710
comprises a conduit fitting portion 720 and a non-metallic portion
730. The non-metallic portion 730, for example, can be manufactured
by a plastic injection molding technique as is well known in the
art. The conduit fitting portion 720 is preferably made of a
material to provide the capsule 710 a rigid metal conduit
mechanical interface structure with more strength than a housing
comprised totally of the non-metallic portion 730 material so that
the conduit port 780 will be in accordance with Article 501 in the
National Electric Code ("NEC") ANSI/NFPA 70-2005. The conduit
fitting portion 720, for example, can be manufactured using any
material which from a mechanical point of view is any physical
element showing very high tensile strength. Such materials include
iron, aluminum, stainless steel, or a non-metallic material with
similar strength to achieve the same result. The conduit fitting
portion 720 provides strength and rigidity over a non-metallic
material, such as glass reinforced plastic, used for the
non-metallic portion 730. While one could attempt to integrate the
conduit fitting portion 720 with the non-metallic portion 730 to
create an integrated single piece housing and manufacture the
integrated housing out of a high-grade non-metallic material in
order to design around or improve the patent, the insubstantial
change to an integrated single piece housing would in effect be
deemed equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0111] In accordance with the present invention, the capsule 710
comprises one non-metallic portion 730 and one conduit fitting
portion 720. While one could attempt to break the non-metallic
portion 730 into two portions comprising a non-metallic portion for
housing the antenna system, whereby allowing radio wave
penetration, and another portion of non-metallic or metallic
material, whereby attempting to design around or improve the
patent, the insubstantial change in dividing the non-metallic
portion 730 to multiple portions would in effect be deemed
equivalent to the present invention since it would perform
substantially the same function, in substantially the same way, to
yield substantially the same result.
[0112] In accordance with the present invention, the capsule 710
comprises one non-metallic portion 730 and one conduit fitting
portion 720 joined together by assembly of two mating threaded
sections with a mating thread joint collar 721. The mating thread
joint collar 721 allows field disassembly and joining of the
non-metallic portion 730 and conduit fitting portion 720. While one
could attempt to use a rabbet joint, straight or flat joint,
labyrinth joint, or the like instead of the mating thread joint
collar 721 as specified in the present embodiment, whereby
attempting to design around or improve the patent, the
insubstantial change to a different type of mating joint would in
effect be deemed equivalent to the present invention since it would
perform substantially the same function, in substantially the same
way, to yield substantially the same result.
[0113] FIG. 8 is an end view of the wireless communication device
700 of FIG. 7, looking at the intrinsically safe circuit interface
port 770.
[0114] FIG. 9 is a cross sectional view of the wireless
communication device 700 of FIG. 7. As illustrated, the
communication device 700 includes the capsule 710 and a plurality
of internal components. The capsule 710 encases the plurality of
internal components, providing covering, protection, and interface
port mechanical structural support. The plurality of internal
components, for example, can include an RF transceiver 945, (or
alternatively a separate RF transmitter and RF receiver (not
shown)), interface lead wires 986 serving as a plurality of conduit
port electrical conductors, first plurality of mating joint
electrical conductors 987, second plurality of mating joint
electrical conductors 988, plurality of intrinsically safe
interface port electrical conductors 976, first intrinsically safe
power supply portion 974, first intrinsically data converter
portion 973, second intrinsically safe power supply portion 984,
second intrinsically data converter portion 983, third
intrinsically safe power supply portion 978, third intrinsically
data converter portion 977, and the like. The plurality of internal
components, in accordance with the present invention, preferably
further includes a first antenna RF switch 952, a second antenna RF
switch 956, a first antenna resonator 951, a second antenna
resonator 954, a third antenna resonator 955, a forth antenna
resonator 957, and an antenna grounding structure 953. The
plurality of internal components further can comprise, as described
previously herein for functionality, of I/O circuit protection,
programmable controllers, a frequency synthesizer, a signal
processor, serial data UART devices, voltage level conditioner
circuits, threshold comparators, A/D converters, D/A converters,
driver circuits, linear regulators, storage capacitors, inductors,
diodes, switch mode controller integrated circuit, and the like.
First printed circuit board 940 and second printed circuit board
942 provide conducted electrical connection and mechanical
structure between the pluralities of internal components within the
wireless communication device 700 as illustrated.
[0115] In accordance with the present invention, an antenna system
for the wireless communication device 700 using a multiple antenna
diversity method, comprises a first antenna resonator 951, a second
antenna resonator 954, a third antenna resonator 955, a forth
antenna resonator 957, a first antenna RF switch 952, a second
antenna RF switch 956, and an antenna grounding structure 953. The
antenna resonators and the antenna grounding structure referred
herein can be built in different ways and using different
technologies as is well known in the art. For example, an antenna
resonator can be a helix-whip coupled to quarter-wave image
grounding structure, a meandered encapsulated flexible circuit, a
meandered none encapsulated flexible circuit, one or more meandered
wires, any combination of active and parasitic radiators, and the
like. The antenna system functions using the combination of all the
mechanical parts that constitute the antenna system and its
switches necessary to carry the RF signal from and towards the RF
transceiver 945 including for example the first antenna resonator
951, the first antenna RF switch 952, coupled between the first
antenna resonator 951 and the RF transceiver 945. The antenna
system is for radiating and collecting radio wave energy and is
coupled and matched to the RF transceiver 945 with circuitry within
the plurality of internal components such as the first antenna RF
switch 952 as is known in the art.
[0116] As illustrated, the antenna system is located within the
non-metallic portion 730 of the capsule 7 loin accordance with the
present invention. Locating the plurality of antenna resonators,
the antenna RF switches, and the antenna grounding structure within
the non-metallic portion 730 decreases the probability of the
antenna system being shielded or detuned from the impedance of
interest, thereby providing consistent overall antenna system
performance efficiency. While one could attempt to use a conduit
portion 720 made of metal as a portion of the antenna resonators or
a portion of the antenna grounding structure instead of locating
them entirely in the non-metallic portion as specified in the
present invention, whereby attempting to design around or improve
the patent, the insubstantial change to the antenna system would in
effect be deemed equivalent to the present invention since it would
perform substantially the same function, in substantially the same
way, to yield substantially the same result.
[0117] As illustrated in FIG. 9, the wireless communication device
700 includes a conduit port 780 for electromechanical interfacing
to a rigid metal electrical conduit connection system or to an
electrical enclosure, junction box, or the like. The conduit
fitting portion 780 has within a conduit sealing compound 982 to
incorporate a factory-installed conduit seal, as previously defined
herein. The factory-installed conduit seal is specified to
withstand a minimum 600 PSIG hydrostatic pressure test applied at
the conduit port 780, whereby the conduit fitting portion 720,
conduit port threaded portion 985, and the conduit sealing compound
982 are designed to withstand the force of an explosion,
eliminating the need for a separate conduit seal at the point where
the device connects to an electrical conduit, an electrical
enclosure, or the like. The interface lead wires protruding out the
conduit port 780, and having the conduit sealing compound 982
forming a seal around each electrical conductor, provide conducted
electrical coupling to the power supply portion 984 and the data
converter portion 983.
[0118] In accordance with the present invention, the conduit port
780 has within a conduit sealing compound 982 to incorporate a
factory-installed conduit seal, as previously defined herein. While
one could attempt to remove the conduit sealing compound 982 in
order to design around or improve the patent, the insubstantial
change would in effect be deemed equivalent since an external
conduit seal must then be installed and the wireless communications
device would perform substantially the same function, in
substantially the same way, to yield substantially the same
result.
[0119] As illustrated in FIG. 9, a conduit sealing compound barrier
981 prevents the conduit sealing compound 982 from entering the
wireless modem cavity 941. While one could attempt to remove the
conduit sealing compound barrier 681 and fill the wireless modem
cavity 941 with a sealing compound or potting material in order to
design around or improve the patent, the insubstantial change would
in effect be deemed equivalent since it would perform substantially
the same function, in substantially the same way, to yield
substantially the same result.
[0120] In accordance with the present invention, the conduit port
threaded portion 985 is specified as an external thread on the
first end of the conduit fitting portion 720 for interfacing to a
rigid metal conduit connection system, or the like. While one could
attempt to use an internal thread for the conduit port threaded
portion 985 instead of an external thread as specified in the
present invention, whereby attempting to design around or improve
the patent, the insubstantial change to the different gender thread
would in effect be deemed equivalent to the present invention since
it would perform substantially the same function, in substantially
the same way, to yield substantially the same result.
[0121] FIG. 9 further illustrates one embodiment of the wireless
modem portion 950 for use within the wireless communication device
700 in accordance with the present invention and the relationship
of the various portions of the wireless modem portion 950 with the
various portions of the capsule 710. As illustrated, the wireless
modem portion 950, in accordance with a preferred embodiment of the
present invention, comprises a printed circuit board 940 and
associated internal components connected therein preferably housed
within the non-metallic portion 730 of the capsule 710 as
previously described herein. The wireless modem 950 further
preferably comprises an antenna system contained within the
non-metallic portion 730 of the capsule 710. The antenna system,
for example, can use a multiple antenna diversity method of a
plurality of antennas comprising a first antenna resonator 951
designed for horizontal polarization, and/or a second antenna
resonator 954 designed for vertical polarization, and/or a third
antenna resonator 955 designed for an alternate frequency band,
and/or a forth antenna resonator 957 designed for spatial diversity
from the first antenna resonator 951. It will be appreciated by
those of ordinary skill in the art that the plurality of antennas
can include any count of one or more antenna resonators or
combination of antenna resonators designed to any combination of
polarizations, frequencies, and spatial diversities as desired in
accordance with the present invention. The antenna resonators
polarization and spatial diversity can include, for example,
vertical polarization, horizontal polarization, quarter wavelength
spatial diversity of the first horizontal polarized antenna,
quarter wavelength spatial diversity of the first vertical
polarized antenna, and the like. It will further be appreciated by
those of ordinary skill in the art that the wireless modem 950 and
its multiple antenna diversity system can be utilized for all
communication protocols such as FHSS (Frequency Hopping Spread
Spectrum), DSSS (Direct Sequence Spread Spectrum), DTS (Digital
Modulation Spectrum), WLAN (Wireless Local Area Network), TDMA
(time division multiple access), CDMA (Code Division Multiple
Access), GSM (Global System for Mobile Communication), and the
like. It will be further appreciated that the wireless modem 950
can be utilized for data transmit and receive such as operating
with GPRS (General Packet Radio Service), EDGE (An edge device is a
physical device that can pass packets between a legacy type of
network such as an Ethernet network and an ATM network, using Data
Link layer and Network layer information), 3G (third-generation
wireless) for facilitating the use of wireless data transfer,
Internet access, and the like.
[0122] As illustrated in FIG. 7, the wireless communication device
700 includes an intrinsically safe circuit interface port 770 for
electromechanical interfacing to an external device, external
transducer module 790, or the like. Such a transducer module 790
may be a camera, microphone, speaker, piezoelectric device,
electrochemical sensor, electromechanical transducer, analog output
transducer, digital output transducer, or the like, and may sense
gas, temperature, pressure, flow rate, vibration, torsion,
mechanical stress, liquid level, or other parameters of interest
which may be monitored periodically or otherwise on command. The
transducer module 790 could comprise of a transducer 992,
transducer module housing 991, transducer electrical conductors
993, and transducer mechanical connector 994. The transducer module
790 may electrically connect through a cable conductor to another
external device for supervisory control of devices such as control
relays, shutoff valves, or the like. The transducer module 790
coupled to the wireless communications device 700 through the
intrinsically safe circuit interface port 770 transmits and/or
receives analog or digital signal and power through the plurality
of intrinsically safe interface port electrical conductors 976.
[0123] In accordance with the present invention, the intrinsically
safe circuit interface port 770 is intrinsically safe for use in
hazardous locations, which is incapable of causing ignition. Thus,
the encapsulated enclosure casting compound 972 within the
intrinsically safe circuit interface port 770 and encapsulating the
plurality of intrinsically safe interface port electrical
conductors 976 provides electrical and mechanical isolation between
the surrounding explosive atmosphere of the capsule and the
ignition sources of the electronic system internal to the capsule.
The intrinsically safe circuit interface port mechanical connector
975 provides a mechanical interface for devices such as the
transducer module 790. The plurality of intrinsically safe
interface port electrical conductors 976 provide electrical
connection to the intrinsically safe power supply portion 974 and
the intrinsically safe data converter portion 973 for external
devices such as the transducer module 790, or the like.
[0124] As illustrated in FIG. 9, an encapsulated enclosure casting
compound barrier 981 prevents the encapsulated enclosure casting
compound 972 from entering the wireless modem cavity 941. While one
could attempt to remove the encapsulated enclosure casting compound
barrier 981 and fill the wireless modem cavity 941 with a sealing
compound or potting material in order to design around or improve
the patent, the insubstantial change would in effect be deemed
equivalent since it would perform substantially the same function,
in substantially the same way, to yield substantially the same
result.
[0125] In accordance with the present invention, the intrinsically
safe circuit interface port 770 comprises an intrinsically safe
circuit interface port mechanical connector 975 and a plurality of
intrinsically safe interface port electrical conductors 976 for
interfacing to external devices such as the transducer module 490,
or the like. By way of example, the preferred embodiment of the
present invention is described in relation to a threaded portion of
the housing as the intrinsically safe circuit interface port
mechanical connector 975 and described in relation to a socket
connector as the plurality of intrinsically safe interface port
electrical conductors 676; however, it will be appreciated by one
of ordinary skill in the art that the present invention is
similarly applicable to an external device, or transducer module
490, or the like, of different mechanical and electrical
interconnections to incorporate different devices or transducer
types that may vary in size and function.
[0126] In accordance with the present invention, the interface lead
wires 986 protruding from the conduit port 780 are coupled to the
second intrinsically safe power supply portion 984 through path of
the third intrinsically safe power supply portion 978, plurality of
first mating joint electrical conductors 987, and plurality of
second mating joint electrical conductors 988, whereby providing a
means for the power supply portion 984 to receive electrical power
from an external source connected to the conduit port 780. The
power supply portion 984 is coupled to the data converter portion
983, the intrinsically safe power supply portion 974, the
intrinsically safe data converter portion 973, and the wireless
modem portion 950, whereby the power supply portion 984 is capable
of providing electrical power to the data converter portion 983,
the intrinsically safe power supply portion 974, the intrinsically
safe data converter portion 973, and the wireless modem portion
950.
[0127] In accordance with the present invention, the interface lead
wires 986 protruding from the conduit port 780 are coupled to the
second intrinsically safe data converter portion 983 through path
of the third intrinsically safe data converter portion 977,
plurality of first mating joint electrical conductors 987, and
plurality of second mating joint electrical conductors 988, whereby
providing a means for the data converter portion 983 to transfer
data with an external electronic device connected to the conduit
port 780. The data converter portion 983 is coupled to the wireless
modem portion 950, whereby providing wireless data communication
ability for an external electronic device connected to the conduit
port 780.
[0128] In accordance with the present invention, the plurality of
intrinsically safe interface port electrical conductors 976 are
coupled to the first intrinsically safe data converter portion 973,
whereby providing a means for the first intrinsically safe data
converter portion 973 to transfer data with an external electronic
device, or transducer module 790, or the like. The first
intrinsically safe data converter portion 973 is coupled to the
wireless modem portion 950, whereby providing wireless data
communication ability for an external electronic device, or
transducer module 790, or the like, connected to the intrinsically
safe circuit interface port 770.
[0129] In accordance with the present invention, the first
intrinsically safe data converter portion 973 further preferably is
coupled to the third data converter portion 977, whereby providing
conducted electrical data communication ability between an external
electronic device connected to the intrinsically safe circuit
interface port 770 and an external electronic device connected to
the conduit port 780.
[0130] As described, the present invention, including utilizing an
antenna system having one or more antenna resonators and
accompanying elements located within a non-metallic portion of a
communication device housing provides a low Specific Absorption
Ratio (SAR) and high efficiency antenna system having a
multi-diversity response in frequency, polarization, and spatial
diversity that is well suited to serve communication systems such
as GPRS and proprietary unlicensed frequency band systems. It
further provides an antenna system that also can be use
indistinctly for FHSS, DTS, WLAN, GSM, TDMA, AMPS and 3G systems
using same or similar form factors. The invention, as described
herein, enables an internal antenna compatible with an
explosion-proof housing structure thereby providing a hazardous
location wireless communications solution for a variety of form
factors. Due to its low sensitivity to accessories and features,
the present invention is further well suited for implementing
intrinsically safe circuits for gas sensors, transducers, video
cameras, and other accessories into wireless communication devices
for hazardous locations while retaining acceptable radio frequency
wireless communications performance. By providing an internal
antenna system component, the present invention reduces system
installation components count and eliminates conduit connections,
thereby reducing the probability of system-level failures caused by
lower-level faults of components and conduit connections, resulting
in a less expensive and safer electrical equipment
installation.
[0131] This disclosure is intended to explain how to fashion and
use various embodiments in accordance with the invention rather
than to limit the true, intended, and fair scope and spirit
thereof. The foregoing description is not intended to be exhaustive
or to limit the invention to the precise form disclosed.
Modifications or variations are possible in light of the above
teachings. The embodiments were chosen and described to provide the
best illustration of the principles of the invention and its
practical application, and to enable one of ordinary skill in the
art to utilize the invention in various embodiments and with
various modifications as are suited to the particular use
contemplated. All such modifications and variations are within the
scope of the invention as determined by the appended claims, as may
be amended during the pendency of this application for patent, and
all equivalents thereof, when interpreted in accordance with the
breadth to which they are fairly, legally, and equitably
entitled.
* * * * *
References